Multi-layered ventilation apparatus and methods of manufacturing thereof

ABSTRACT

Disclosed is an apparatus for venting buildings, specifically attic spaces, such vents being predominantly shape-conform to the components from which a wall or a roof is built (typically tiles, in the context of roofs), the vent typically being fabricated from a metallic, plastic, or ceramic core as well as one or more layers from other materials or compounds which modify the overall characteristics of the vent, such as the surface characteristics. Furthermore disclosed are methods of manufacturing such ventilation apparatuses.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates to ventilation of buildings, and more precisely topredominantly shape-conform roof vents with enhanced properties.

Description of the Related Art

The proper ventilation of buildings and houses is important to maintainsuitable humidity levels, to help maintain acceptable temperature insidethe building while reducing costs for heating or cooling, and formaintaining indoor air quality.

In some cases such ventilation systems comprise ducts through which airfrom the inside of a building is channeled towards the roof. In othercases the ventilation systems primarily serve to ventilate the atticspaces of a building. In some instances these may be passive ventilationsystems and in other instances active systems, such as activeventilation systems driven by a fan.

In many such cases vents are needed which are typically placed on theroof or sometimes on the walls of buildings. The principle function ofthe vent is to enable air inflow or outflow while reducing, or in somecases, effectively eliminating penetration of water (rain, snow, ice),debris, vermin, insects, embers, or other unwanted material into thebuilding.

Sometimes, vents are integrated into the roof or wall in a shape-conformmanner in order to reduce the disturbance to the optical appearance ofthe roof or wall. In case of vents which are placed on the roof of abuilding, the vents may be shaped, colored, and surface-structured likeclay or concrete tiles and are then often referred to as vent tile orventilation roof tile.

For example, Harry O'Hagin describes in U.S. Pat. No. 6,447,390 B1 a“Method and Apparatus for Roof Ventilation,” which entails variousstyles of roof vents which are “generally conforming to and are adaptedto be mounted . . . among a plurality of roof tiles”. Furthermore, HarryO'Hagin and Carolina O'Hagin describe in U.S. Pat. No. D458,392 S a“tile roof with a cloaked roof vent”. Similarly, Harry O'Hagin describesin EP 0 980 498 B1 an attic vent which attempts to match the surroundingtilted tile roofs appearance and wherein the “vent skeleton being formedof a single piece of material”.

Such conventional vents are typically made from a single material, likemetal, such as sheet metal, or in some cases, steel, or in some casesaluminum, copper, or other metals, or a single alloy thereof. Whilethese materials allow the manufacture of such vents in a cost effectivemanner, the physical and chemical properties of the vent are limited tothe material properties of the single material, such as sheet metal, ofwhich they are made.

Therefore, there is a mismatch between said physical and chemicalproperties and those of the actual roof or wall, which is typicallymanufactured from concrete, clay, ceramics, or wood. Furthermore,certain levels of physical and chemical properties can simply not bereached with a ventilation roof tile solely manufactured from sheetmetal.

Hence there is need for a way to tailor the properties of vents in sucha way that additional, overall properties can be achieved which may notbe achieved with vents that are predominantly a single metallic,plastic, or ceramic material. Multi-layered, multi-functional systemscan provide such capabilities.

SUMMARY OF THE INVENTION

For purposes of summarizing the invention and the advantages achievedover the prior art, certain objects and advantages of the invention havebeen described herein. Of course, it is to be understood that notnecessarily all such objects or advantages may be achieved in accordancewith any particular embodiment of the invention. Thus, for example,those skilled in the art will recognize that the invention may beembodied or carried out in a manner that achieves or optimizes oneadvantage or group of advantages as taught herein without necessarilyachieving other objects or advantages as may be taught or suggestedherein.

All of these embodiments are intended to be within the scope of theinvention herein disclosed. These and other embodiments of the presentinvention will become readily apparent to those skilled in the art fromthe following detailed description of the preferred embodiments havingreference to the attached figures, the invention not being limited toany particular preferred embodiment(s) disclosed.

The principle of the invention is to provide vents, such asshape-conform vents, which include a metallic, plastic, or ceramic core,as well as one, two, or more additional layers including other materialsor compounds, which modify the overall characteristics of the vent, suchas the surface characteristics. The metallic, plastic, or ceramic corecan provide shape and mechanical stability, whereas the additionallayers can enable additional beneficial effects.

In some embodiments the core material of the vent, such as ashape-conform vent, is modified at the surface in such a way thateffectively a multi-layered material is produced. In some embodimentsthe disclosed multi-layered shape-conform vent also serves at least inpart to protect at least to some degree at least one underlaying elementfrom detrimental environmental influences. In some such embodiments thiscan serve to extend the lifetime of said at least one underlyingelement.

The method of manufacturing the core itself may differ, depending on thematerial used. For example, sheet-metal may be cut, bent and welded orriveted, whereas a plastic core may for example be produced by a hotdeforming process or by injection molding, or other processes. A ceramiccore may, for example be produced by a sinter-like process or byinjecting wet clay in a suitable form, or other processes, possibly intwo or more steps.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates schematically an embodiment of the disclosedinvention, as applied to an M-style clay tile roof. At the top of FIG.1, a 3-D view of a section of a roof, including a plurality of tiles101, is shown. At the center of this section is a predominantly shapedconform vent shown, the visible part of which comprises two convex outerelements 102 and one concave element 103. At the center of FIG. 1 ahorizontal cross-section through this roof section including thepredominantly shaped conform vent is shown, schematically illustratingthis embodiment of a roof vent. As can be seen in the enlargement ofthis cross section at the bottom of FIG. 1, the elements 102 and 103comprise the actual core structures 1021 and 1031, onto which twoadditional layers 1022 and 1023 have been added. For example, layer 1022may be predominantly hydrophobic or super-hydrophobic, and layer 1023may for example serve to improve the thermal insulation of the vent.

FIG. 2 illustrates schematically an embodiment of the disclosedinvention employed within an M-shaped concrete tile roof. In someembodiments of such roofs a single concrete tile can resemble two ormore conventional tiles. At the top of FIG. 2 a 3-D view a section of aroof, including a plurality of tiles 201, is shown. At the center ofthis section is a predominantly shaped conform vent shown, the visiblepart of which comprises an outer element 202, sometimes referred to as“outer vent cover,” which has typically two or three, or morecylindrical and convex sections. There can also be one or more innerelements, sometimes referred to as “subflashing” or “primary vent cover”and which are not shown in FIG. 2. At the center of FIG. 2 a crosssection through this roof section including the predominantly shapedconform vent is shown, schematically illustrating this embodiment of aroof vent. (In this case the cross section is taken at a location whereno orifices in element 202 can be seen, though which air flow occurs.)As can be seen in the enlargement of this cross section at the bottom ofFIG. 2, the element 202 comprises the actual core structures 2021, ontowhich two additional layers 2022 and 2023 have been added. For example,layer 2022 may be predominantly hydrophobic or super-hydrophobic, andlayer 2023 may for example serve to improve the thermal insulation ofthe vent.

FIG. 3 illustrates schematically an embodiment of the disclosedinvention employed within a S-shaped concrete tile roof. Typically asingle tile has the cross section resembling an “S,” for example, thegeometric shape is formed by two parallel, inverted cylinder wallsections, but in some cases the tile comprises one convex cylinder wallsection and one predominantly flat section. At the top of FIG. 3 a 3-Dview a section of a roof, including a plurality of tiles 301, is shown.At the center of this section is a predominantly shaped conform ventshown, the visible part of which, sometimes referred to as “outer ventcover,” comprises two predominantly cylindrically convex elements 302and two predominantly cylindrically concave elements 303. There can alsobe one or more inner elements, sometimes referred to as “subflashing” or“primary vent cover,” and which are not shown in FIG. 3. At the centerof FIG. 3 a cross section through this roof section including thepredominantly shaped conform vent is shown, schematically illustratingthis embodiment of a roof vent. As can be better seen in the enlargementof this cross section at the bottom of FIG. 3, the element 302 comprisesthe actual core structures 3021, onto which two additional layers 3022and 3023 have been added. The same layers 3022 and 3023 have been addedto the cores of the convex elements 3031. For example, layer 3022 may bepredominantly hydrophobic or super-hydrophobic, and layer 3023 may forexample serve to improve the thermal insulation of the vent.

FIG. 4 illustrates schematically an embodiment of the disclosedinvention employed within a flat clay tile roof. At the top of FIG. 4 a3-D view a section of a roof, including a plurality of tiles 401 isshown. At the center of this section is a predominantly shaped conformvent shown, the visible part of which comprises a predominantly flatouter element 402, sometimes referred to as “outer vent cover as well asone or more inner elements, sometimes referred to as “subflashing” or“primary vent cover,” and which are not shown in FIG. 4. At the centerof FIG. 4 a cross section through this roof section including thepredominantly flat vent is shown, schematically illustrating thisembodiment of a roof vent. As can be better seen in the enlargement ofthis cross section at the bottom of FIG. 4, the element 402 comprisesthe actual core structure 4021, onto which two additional layers 4022and 4023 have been added. For example, layer 4022 may be predominantlyhydrophobic or super-hydrophobic, and layer 4023 may for example serveto improve the thermal insulation of the vent.

FIG. 5 illustrates schematically an embodiment of the disclosedinvention employed within shingle, or slate & shake roofs. At the top ofFIG. 5 a 3D view a section of a roof, including a plurality of shingles501 or larger predominantly flat plates, which are structures such as toresemble shingles. At the center of this section is a predominantlyshaped conform vent shown, the visible part of which comprises apredominantly flat outer element 502, sometimes referred to as “outervent cover”.

The appearance is similar to the vent shown in FIG. 4. There are alsoinvisible inner elements, sometimes referred to as “subflashing” or“primary vent cover,” and which are not shown in FIG. 5. At the centerof FIG. 5 a cross section through this roof section including thepredominantly flat vent is shown, schematically illustrating thisembodiment of a roof vent. As can be better seen in the enlargement ofthis cross section at the bottom of FIG. 5, the element 502 comprisesthe actual core structure 5021, onto which two additional layers 5022and 5023 have been added. For example, layer 5022 may be predominantlyhydrophobic or super-hydrophobic, and layer 5023 may for example serveto improve the thermal insulation of the vent.

DETAILED DESCRIPTION

Roof vents are typically made from sheet metal and in certain casesshaped like tiles from which the entire roof is made, i.e.,shape-conform thereby visually blending into the roof. In someembodiments these may be mission style, or S-style, or Villa-style, orso-called Japanese-style vent tiles. In some embodiments these may beflat tiles vents in order to match very smooth and flat roofs. The ventcontains gaps which are located in such a way that a visual disturbancecan be reduced, air flow can be increased, and penetration of water intothe house can be reduced, or even essentially eliminated.

According to the disclosed invention such shape-conform vents can bemade not only of said sheet metal, plastic, or ceramic but comprise atleast one additional layer which changes some of the chemical ofphysical properties of the vent. In some embodiments one or moreadditional layers may be employed either above or below the metallic,plastic, or ceramic core. Furthermore, in an embodiment the disclosedpredominantly shape-conform multi-layered vents have a size which is aninteger multiple of the size of the actual roof tiles.

Various methods of producing multilayer materials can be used, whichaccording to the present invention are used to fabricate shape-conformmulti-layered ventilation apparatuses. Several properties of the ventcan thereby be enhanced.

Types of Layers

In one embodiment of the disclosed invention at least a singleadditional layer is used to change the behavior of the surface of theventilation apparatus with respect to water, which can have one or morebeneficial effects. In one embodiment a hydrophobic layer (contact angletypically larger than 90°), or even a super-hydrophobic layer (contactangle typically larger than 150°) is applied to the surface of theshape-conform vent. Such a layer will reject water and thus reduce thetendency of the vent to accumulate dirt, to corrode, or to leak. Also,on super-hydrophobic surfaces small water droplets are formed on top ofthe surface, hardly touching instead of wetting the surface, and thesedroplets are removed by even very slow air movements, in fact collectingand removing other dust and dirt particles in the process.

In an embodiment, the hydrophobic layer is applied to the sheet metalprior to forming the actual ventilation apparatus from it. In anotherembodiment the hydrophobic layer is applied to ventilation apparatusafter it has been built from sheet metal. In yet another embodiment thehydrophobic layer is applied previously fabricated and already installedroof vents which are predominantly made from one material. Inparticular, kits may be provided to both contractors and end users whichpermit to apply such a hydrophobic or super-hydrophobic layer to alreadyinstalled predominantly shape-conform vents. In some embodiments such acoating has to be reapplied by the contractor or end user after acertain time in order to sustain a certain level of effectiveness.

In some embodiments the hydrophobic layer may be created by polymers,incl. polyurethane (PU), acrylates, silicones, PVC, plastisols, i.e., adispersion of PVC resins in a plasticiser. Examples are given later. Insome such embodiments the plasticiser may be a phthalate, including forexample dioctyl phthalate, ditridecyl phthalate, or diisodecylphthalate.

In some embodiments the hydrophobic layer may be transparent and inother embodiments also serve to achieve a specific color of the vent.

In some embodiments, super-hydrophobic, or self-cleaning, layers may beapplied or the surface of the predominantly shape-conform vent, or thesurface of the vent may be modified by a suitable process in such a waythat nanostructures are created on said surface, thereby obtaining asuper-hydrophobic effect. In some embodiments the hydrophobic orsuper-hydrophobic effect may be created by a combination of applyingadditional material and a process to physically or chemically modify thesurface.

In some embodiments these nanoparticles may be naturally occurring ormay be synthesized.

In some embodiments the hydrophobic layer may be based on titania orsilica particles and applied by a sol-gel process.

In some embodiments one or more of the additional layers may containnanoparticles. In some embodiments the layer or layers are based on purezinc oxide (ZnO) nanoparticles, zinc oxide polystyrene (ZnO/PS)nanocomposites, precipitated calcium carbonate, carbon nanotubes,manganese oxide polystyrene (MnO₂/PS) nanocomposite, silicananoparticles, aluminosilicate nanoparticles, titanium dioxide TiO₂nanoparticles, silicon dioxide SiO₂ nanoparticles, or other suitablenanoparticles or mixtures thereof. In some special embodiments asuper-hydrophobic layer may be based on metal matrix composites. In someembodiments the one or more additional layers may contain metallicnanoparticles embedded in a ceramic matrix. In other embodiments the oneor more additional layers may contain nanoparticles embedded inpoly(dimethylsiloxane) (PDMS). Additional examples are given below.

In some embodiments silica-based gel films may be modified with afluorinated silane. In some embodiments layers may be produced bycoating the surface with long-chain alkanoic acids.

In some embodiments one or more of the additional layers may containcalcium carbonate CaCO₃ nanoparticles (optionally additionallychemically modified) and embedded in a binder, typically an acrylatepolymer, resulting in a hydrophobic or super-hydrophobic effect.

In some embodiments one or more of the additional hydrophobic orsuper-hydrophobic layers on the predominantly shape-conform vent coremay be produced by a nanostructured composites formed fromparticle-polymer dispersions.

In some embodiments one or more of the additional hydrophobic odersuper-hydrophobic layers on the predominantly shape-conform vent coremay be formed by a composite of a polyurethane matrix and nanoparticlesfrom silicate type minerals, specifically phyllosilicate type minerals,and more specifically in some embodiments nanoparticles fromMontmorillonite, Vermiculite, Kaolinite, Palygorskite or Pyrophyllite.Such materials can under certain conditions form hierarchical nano- andmicro-scale topology, which results in string hydrophobicity. Inaddition, these nanoparticles may be chemically modified by the use ofaminosilanes, e.g. (3-Aminopropyl)triethoxysilane, and polyamines (e.g.octadecylamine). The polyurethane matrix may be formed by using amoisture-curable polyurethane formula including a smaller component ofmethylene diphenyl diisocyanate (MDI) and a larger portion ofpolyurethane pre-polymer.

In some embodiments one or more of the additional hydrophobic odersuper-hydrophobic layers on the predominantly shape-conform vent coremay be formed by aluminum oxide Al₂O₃ nanoparticles suspended in asilicone rubber matrix. Such a layer may be created by firstultrasonically cleaning the vent core (for example in acetone), and thenapplying a solution of aluminum oxide nanoparticles, solvent (e.g.acetone), and silicone rubber. In some embodiments the nanoparticles matbe embedded in room temperature vulcanizing (RTV) silicone rubber.

In some embodiments one or more of the additional hydrophobic odersuper-hydrophobic layers on the predominantly shape-conform vent coremay be comprise an elastomeric nanostructured composite formed from byapplying (e.g. spaying) nanostructured carbon black particles (or othercarbon nanoparticles) as well as submicrometer-sizedpoly(tetrafluoroethylene) particles both dispersed in a nitrile rubbersolution in acetone.

In some embodiments an additional layer may be added to thepredominantly shape-conform roof vent, which comprises a syntheticfluoropolymer, specifically polytetrafluoroethylene (PTFE). In someembodiments film a hydrophobic or super-hydrophobic layer is produced byfirst depositing nanoparticles on the vent core and in a second stepovercoating these nanoparticles by a layer of plasma sputtered PTFE.

In some embodiments an additional hydrophobic or super-hydrophobic layermay be added to the predominantly shape-conform vent core by applying asuspension of a mixture of titanium dioxide TiO₂ nanoparticles and zincoxide ZnO nanoparticles in perfluoroalkylacrylate (PAA).

In some embodiments an additional hydrophobic or super-hydrophobic layermay be added to the predominantly shape-conform vent core by applying asuspension of titanium dioxide TiO₂ nanowires in tetrahydrofuran (THF)and poly(dimethylsiloxane)(PDMS).

In some special embodiments the vent may predominantly be fabricatedfrom a multi-functional composite material. For example, sincesuper-hydrophobic layers can be susceptible to wear, in some embodimentsthe super-hydrophobic component is actually embedded in the corematerial of the predominantly shape-conform vent, thereby formingeffectively a multi-functional composite material.

Similarly, in some embodiments the surface of the predominantlyshape-conform roof vent may also be modified either via processingand/or through additional layers to also exhibit icephobic, oranti-iceing, properties, i.e., the surface of the vent does not allowthe formation of ice on it, or at least substantially reduces thetendency to form ice. This can be desirable since it reduces the rate ofcorrosion of the metal core and reduces the probability of leaks. Undersome conditions said super-hydrophobic surfaces will also exhibiticephobic effects, since water droplets, which form at the surface, haveinsufficient adhesion, and once frozen, get blown away even by very lowwinds speeds.

Pure sheet metal vents constitute a thermal leak compared to the actualroof. Thus, in another embodiment the goal of the multi-layer design isto attempt to match the thermal properties of surrounding roof, matchingthe heat conductivity of clay or concrete tiles thus achieving betterthermal insulation.

In an embodiment a ceramic layer may be added to the metallic corestructure of the predominantly shape-conform vent acting as a thermalbarrier and thereby reducing the heat conductivity of the entirestructure. Such an additional layer may typically be made from Al₂O₃ orMullite, but other comparable ceramics known to those skilled in the artare obviously also possible. In an embodiment, the ceramic layer may beporous in order to increase thermal insulation.

In yet another embodiment of the disclosed invention, a relatively thinceramic layer may be added to the top of the metallic plastic, orceramic core of the predominantly shape-conform vent, which closelymatches the appearance of the ceramic, clay or concrete tiles from whichthe roof is made thereby achieving almost complete camouflage.

In yet another embodiment of the disclosed invention, a rubber orrubber-like layer may in part be added to the underside of the metallic,plastic, or ceramic core of the shape-conform vent in order to enablebetter sealing against neighboring tile and reduce the chance for waterleaks. The rubber or rubber-like layer may will also permit the achievewater tight installation despite mechanical tolerances, including slightbending, of the metal plastic or ceramic core.

In yet another embodiment of the disclosed invention the additionallayer or layers may serve to reduce the tendency of the typicallysheet-metal based core of the predominantly shape-conform vent tocorrode.

In yet another embodiment of the disclosed invention the additionallayer or layers may serve to produce electricity, i.e. be predominantlyphoto-voltaic.

In some embodiments only portions of the vent core are covered with oneor more additional layers. In some embodiments predominantly portions ofthe vent core which are exposed to the outside, i.e., are exposed torain, snow, and sunlight are covered with one or more additional layers.

Methods of Deposition and Surface Modification

As previously mentioned, the various layers are applied to the corematerial in some embodiments to the material of the core prior toforming the actual ventilation apparatus from it and in some embodimentsafter the vent has been built from the core material.

Various methods of achieving a multi-layered, predominantlyshape-conform vent may be used, which ultimately determines the type ofbond which is created between the core structure and the additionallayers.

In some embodiments the layer or layers are created by a Physical VaporDeposition (PVD) process in a vacuum chamber such as magnetronsputtering (either DC or RF), whereby a plasma is created (typicallyfrom Argon) which sputters the material to be deposited from a targetand deposits the atoms on a substrate, in this case the roof vent or itsraw material. One advantage of sputtering is that even thermallysensitive materials like plastics can be coated. Another possible PVDtechnique is electron beam evaporation, whereby a high power electronbeam evaporates the material to be deposited and the vapor then coatsthe roof vent or its raw material.

In some embodiments the sputtering process may create alloy layers onthe roof vent or its raw material by sputtering compound targets or bysimultaneously sputtering from several targets, by reactive sputtering,or a combination thereof. Similarly, alloy layers can be created byelectron beam evaporation simultaneously from several crucibles. Onefinal sputtering process step may also be used to create a thin finallayer that achieves a desired color of the roof vent. In someembodiments a sputtering process may also be used to modify thestructure, roughness, or cleanness of the surface (i.e., a plasma etch)of the predominantly shape-conform vent or its raw material.

Both magnetron sputtering and electron beam evaporation, whilerelatively expensive, are ideally suited to create films withextraordinary properties and of materials with very high melting andevaporation temperatures, such as various ceramics or some metals.

In some implementations also a Chemical Vapor Deposition process (CVD)may be used to form layers on the predominantly shape-conform vent orits raw core material. In some embodiments this may be a Plasma-EnhancedChemical Vapor Deposition (PECVD) process.

In some embodiments an additional layer or layers are created by anelectrochemical process, including but not limited to electroplating(electrodeposition or electroforming), or electrolytic passivation(anodization). In some embodiments an additional layer or layers arecreated by an electro-physical process, including but not limited toelectrospraying or modified forms of electrospinning.

In some embodiments the layer or layers are created by a thermal sprayprocess, including variants thereof such a detonation spray coating(DSC) which is particularly well suited for uniform thick coatings ofcomplex surfaces, and whereby in general a feedstock of material, oftenprovided as a powder, is molten, and then accelerated by a gas stream,and then propelled onto the vent or its raw material to form the desiredlayer. Metallic, including alloys, or ceramic layers may be created onthe vent by such a method. Also, PTFE layers may be created onpredominantly shape-conform vent by this method. In some embodimentsthis is to be followed by a high-temperature curing process.

In some embodiments the layer or layers are created by a laser assistedsurface coating process. In some such embodiments the layer or layersare created by laser surface alloying (LSA) whereby a thin layer at thesurface of the metal core of the predominantly shape-conform vent ismelted by a high power laser beam with the simultaneous addition of thedesired alloying element, thereby changing the surface chemicalcomposition of the metal core. In some other similar embodiments thelayer or layers are created by laser cladding or laser beam hardfacing.Typically a beam from a high-power IR laser, again mostly Nd:YAG or CO₂is scanned across the surface and the material, which is to bedeposited, is simultaneously supplied as a powder via gas jet injectionsystem to point where the laser hits the vent or its raw material. Thelaser then melts and fuses the powder and creates a uniform layer on thesurface.

In some embodiments a quasi-layer or layers are created from the corematerial of the vent by using a Laser to modify the surface of said corematerial. Typically a beam from a pulsed high-power IR laser, mostlyNd:YAG or CO₂, is scanned across the surface and the core material ismolten and then re-solidifies assuming different properties and orappearance.

In some embodiments the layer or layers are created by Plasma TransferArc process, whereby typically under atmospheric conditions a plasma iscreated—usually referred to as plasma transfer arc—between an electrodeand the vent or its raw material, and simultaneously the material to becoated is supplied as a stream of powder which is molten and fused tothe surface of the vent by the plasma. Since the material to be coatedis part of an electric circuit, this embodiment is only applicable tovents with cores made from metal. Plasma Transfer Arc methods arespecifically well suited for high throughput processing and relativelythick, dense and crack-free layers of several mm thickness can beproduced, both from metal alloys and ceramics.

In some embodiments the layer or layers are created by a bondingprocess, which can be well suited for additional layers of increasedthickness, for example of parts made from ceramics, the thickness ofwhich may exceed the thickness of the core structure of the vent.

In some embodiments the layer or layers are created by gluing, which canalso be well suited for additional layers of increased thickness, forexample of parts made from ceramics, the thickness of which may exceedthe thickness of the core structure of the vent. In one such embodimentthe layer or layers are created by a laminating process.

In some embodiments the layer or layers are created by sol-gel processwhereby from precursors, typically metal alkoxides, a colloidal solution(sol) of monomers is created, which acts as the precursor for anintegrated network (gel) of either discrete particles or networkpolymers.

In some embodiments the layer or layers are created by layer-by-layer(LBL) assembly technique. For example, in some embodiments, on steelsurfaces a first layer may be produced with an solution ofPoly(diallyldimetylammonium) (PDDA) and or poly(sodium4-styrenesulfonate) (PSS). Then, a subsequent layer may be producedusing a suspension of Silica SiO₂ nanoparticles or TiO₂ nanoparticles.Typical particle sizes are of the order of several 10s of nm, frequentlybetween 10 and 40 nm. A thermal step (baking) may follow in someembodiments. A further step may comprise using a methanolic solution ofperfluorodecyltriethoxysilane (PTES), followed by another thermal step.In some embodiments pure N₂ or other suitable, cleaned and dry gasses orgas mixtures may be used for drying the surfaces.

In some embodiments the layer or layers are created by painting, spraypainting, spin coating, dip coating, or in general a low temperaturecoating process.

In embodiments the layer or layers are created by dissolving one or morepolymers with a solvent, for example methyl, ethyl, ketone, dimethylformamid, totuol or others, and applying the solution to the surface ofthe predominantly shape-conform vent or to the raw material prior toforming a predominantly shape-conform vent, and letting the solutionsolidify. Additional components may be added to the solution. In someembodiments a layer can be created by spraying and by spin-coating afluoropolymer incorporated with SiO₂ and or TiO₂ nanopowder onto thecore structure.

In some embodiments the layer or layers are created by anatomized-spray-plasma deposition (ASPD) process, whereby an ultrasonicnozzle generates a mist of small droplets (typically around 20 μm to 30μm in size). Subsequently, plasma-excited species (VUV, electrons, ions)initiate polymerization at the carbon-carbon double bond for theprecursor molecules contained within the droplets in addition toactivating the substrate surface. Polymer chain growth occurs alreadywithin the droplets, which ultimately leads to a stable layer, oncedeposited on the surface.

In some embodiments a solution of nanoparticles may be used for spraycasting. For example, the nanoparticle solution may be composed of amixture of ZnO nanoparticles, an organosilicon compound, specifically aorganosilane quaternary nitrogen compound (acting as binder), and ethylacetate. In some embodiments the mixture may be primarily composed ofethyl acetate (on the order of 80% or less by weight), on the order of20% or less organosilane quaternary nitrogen compound. andcorrespondingly of only a few (single digit) percent of the ZnOnanoparticles. Thereby an effective dispersion of the nanoparticles insolution may be achieved. The solution may be sprayed onto the surfaceof the predominantly shape-conform vents using a double action airbrushfor atomizing the spray and producing thin hydrophobic or evensuper-hydrophobic coatings.

In some embodiments this process may be conducted in a controlledatmosphere, for example, using filtered and/or pure gases, and/or underreduced gas pressure.

Although the invention has been disclosed in the context of certainembodiments and examples, it will be understood by those skilled in theart that the invention extends beyond the specifically disclosedembodiments to other alternative embodiments and/or uses and obviousmodifications and equivalents thereof. Accordingly, the invention is notintended to be limited by the specific disclosures of preferredembodiments herein.

What is claimed is:
 1. A ventilation apparatus comprising: at least oneshape predominantly conforming in predominantly two dimensions to astructure of one or more components from which a wall or a roof of abuilding is made, wherein the two dimensions extend approximatelyparallel to a plane formed by the wall or the roof, and wherein theapparatus permits airflow into or out of the building predominantlythrough the plane formed by the wall or the roof; a predominantlymetallic, plastic, or ceramic vent core; and at least one layer ofmaterial with chemically or physically substantially differentproperties than the core, such that at least one functionalcharacteristic of the ventilation apparatus differs compared to anotherventilation apparatus using only the vent core material; wherein the atleast one layer is on the vent core and exhibits the property of beinghydrophobic, super-hydrophobic, icephobic, anti-icing, or anycombinations thereof; and wherein the at least one layer is selectedfrom (i) a single type of nanoparticle deposited onto the vent core;(ii) a mix of different types of nanoparticles deposited onto the ventcore; or (iii) a nanostructured surface created on the vent core.
 2. Theventilation apparatus according to claim 1 wherein the at least onelayer is produced by predominantly depositing polymers or polymerprecursors.
 3. The ventilation apparatus according to claim 1 whereinthe at least one layer is produced by predominantly depositing at leastone silicone or silicone precursor.
 4. The ventilation apparatusaccording to claim 1 wherein the at least one layer is produced bypredominantly depositing at least one synthetic fluoropolymer or itsprecursor.
 5. The ventilation apparatus according to claim 1 wherein theat least one layer is produced on a raw material used to form the ventcore prior to forming the vent core.
 6. The ventilation apparatusaccording to claim 1 wherein the at least one layer is produced on thevent core after forming the vent core.
 7. The ventilation apparatusaccording to claim 1 wherein the at least one layer is produced on theventilation apparatus after it has been installed in a building.
 8. Theventilation apparatus according to claim 1 wherein the at least onelayer is directly on the vent core.
 9. The ventilation apparatusaccording to claim 1 wherein the at least one layer is on the vent core,said layer having a substantially different thermal conductivity thanthe vent core.
 10. The ventilation apparatus according to claim 9wherein the at least one layer is produced on a raw material used toform the vent core prior to forming the vent core.
 11. The ventilationapparatus according to claim 9 wherein the at least one layer isproduced on the vent core after forming the vent core.
 12. Theventilation apparatus according to claim 9 wherein the at least onelayer is produced on the ventilation apparatus after it has beeninstalled in a building.
 13. The ventilation apparatus according toclaim 1 wherein the at least one layer has a substantially differentoptical reflectivity than the vent core.
 14. The ventilation apparatusaccording to claim 13 wherein the at least one layer is produced on araw material used to form the vent core prior to forming the vent core.15. The ventilation apparatus according to claim 13 wherein the at leastone layer is produced on the vent core after forming the core vent. 16.The ventilation apparatus according to claim 13 wherein the at least onelayer is produced on the ventilation apparatus after it has beeninstalled in a building.
 17. The ventilation apparatus according toclaim 1 wherein the at least one layer is configured to mimic the visualappearance and surface texture of a surrounding wall or roof.
 18. Theventilation apparatus according to claim 1 wherein the at least onelayer is produced by a physical vapor deposition process.
 19. Theventilation apparatus according to claim 1 wherein the at least onelayer is produced by a process or technique selected from the groupconsisting of (a) a chemical vapor deposition or plasma-enhancedchemical vapor deposition process; (b) an electro-chemical process; (c)a thermal spray process; (d) a laser assisted surface coating process;(e) a plasma transfer arc process; (f) a bonding process; (g) a sol-gelprocess; (h) a layer-by-layer assembly technique; (i) anatomized-spray-plasma deposition process; and (j) a low temperaturecoating process of painting, spray painting, spin coating, or dipcoating.
 20. The ventilation apparatus according to claim 1 wherein theat least one layer is formed predominantly from metal.
 21. Theventilation apparatus according to claim 1 wherein the at least onelayer is formed predominantly from ceramic.
 22. The ventilationapparatus according to claim 1 wherein the at least one layer is formedfrom predominantly one or more dissolved polymers.
 23. The ventilationapparatus according to claim 1 wherein the at least one layer is formedby applying predominantly one or more polymer precursors and finishingpolymerization thereafter.
 24. The ventilation apparatus according toclaim 1 wherein the at least one layer is formed by applyingpredominantly one or more silicones or silicone precursors.
 25. Theventilation apparatus according to claim 1 wherein the at least onelayer is formed by applying predominantly at least one syntheticfluoropolymer or its precursors.
 26. The ventilation apparatus accordingto claim 1 wherein the at least one layer contains nanocompositematerials.
 27. The ventilation apparatus according to claim 1 whereinthe at least one layer is formed by a process selected from the groupconsisting of: a) embedding at least one type of nanoparticle in amatrix material; b) depositing predominantly metal oxide nanoparticlesembedded in a predominantly polymer based matrix; c) depositingpredominantly metal oxide nanoparticles embedded in a predominantlyacrylate polymer based matrix; d) depositing predominantly metal oxidenanoparticles embedded in a predominantly silicone based matrix; e)depositing predominantly metal oxide nanoparticles embedded in apredominantly synthetic fluoropolymer based matrix; f) depositingpredominantly carbon nanoparticles embedded in a predominantly polymerbased matrix; g) depositing predominantly carbon nanoparticles embeddedin a predominantly acrylate polymer based matrix; h) depositingpredominantly carbon nanoparticles embedded in a predominantly siliconebased matrix; i) depositing predominantly carbon nanoparticles embeddedin a predominantly synthetic fluoropolymer based matrix; j) depositingpredominantly naturally occurring nanoparticles embedded in apredominantly polymer based matrix; k) depositing predominantlynaturally occurring nanoparticles embedded in a predominantly acrylatepolymer based matrix; l) depositing predominantly naturally occurringnanoparticles embedded in a predominantly silicone based matrix; m)depositing predominantly naturally occurring nanoparticles embedded in apredominantly synthetic fluoropolymer based matrix; n) depositingpredominantly metal nanoparticles embedded in a predominantly polymerbased matrix; o) depositing predominantly metal nanoparticles embeddedin a predominantly acrylate polymer based matrix; p) depositingpredominantly metal nanoparticles embedded in a predominantly siliconebased matrix; q) depositing predominantly metal nanoparticles embeddedin a predominantly synthetic fluoropolymer based matrix; r) depositing acomposite of a matrix and at least a single type of nanoparticles or amix of different types of nanoparticles and wherein said nanoparticlesare embedded into the matrix; s) depositing predominantly at least onetype of nanoparticle embedded in a matrix of predominantly polymers orpolymer precursors; t) depositing predominantly at least one type ofnanoparticle embedded in a matrix of predominantly silicones or siliconeprecursors; and u) depositing predominantly at least one type ofnanoparticle embedded in a matrix of predominantly syntheticfluoropolymers or synthetic fluoropolymer precursors.
 28. A ventilationapparatus comprising: at least one shape predominantly conforming inpredominantly two dimensions to a structure of one or more componentsfrom which a wall or a roof of a building is made, wherein the twodimensions extend approximately parallel to a plane formed by the wallor the roof, and wherein the apparatus permits airflow into or out ofthe building predominantly through the plane formed by the wall or theroof; a predominantly metallic, plastic, or ceramic vent core; and atleast one layer of material with chemically or physically substantiallydifferent properties than the core, such that at least one functionalcharacteristic of the ventilation apparatus differs compared to anotherventilation apparatus using only the vent core material; wherein the atleast one layer is on the vent core and exhibits the property of beinghydrophobic, super-hydrophobic, icephobic, anti-icing, or anycombinations thereof; and wherein the at least one layer containsnanocomposite materials.
 29. The ventilation apparatus according toclaim 28 wherein the at least one layer is selected from (i) a singletype of nanoparticle deposited onto the vent core; (ii) a mix ofdifferent types of nanoparticles deposited onto the vent core; or (iii)a nanostructured surface created on the vent core.
 30. The ventilationapparatus according to claim 28 wherein the at least one layer isproduced by predominantly depositing polymers or polymer precursors. 31.The ventilation apparatus according to claim 28 wherein the at least onelayer is produced by predominantly depositing at least one silicone orsilicone precursor.
 32. The ventilation apparatus according to claim 28wherein the at least one layer is produced by predominantly depositingat least one synthetic fluoropolymer or its precursor.
 33. Theventilation apparatus according to claim 28 wherein the at least onelayer is produced on a raw material used to form the vent core prior toforming the vent core.
 34. The ventilation apparatus according to claim28 wherein the at least one layer is produced on the vent core afterforming the vent core.
 35. The ventilation apparatus according to claim28 wherein the at least one layer is produced on the ventilationapparatus after it has been installed in a building.
 36. The ventilationapparatus according to claim 28 wherein the at least one layer isdirectly on the vent core.
 37. The ventilation apparatus according toclaim 28 wherein the at least one layer is on the vent core, said layerhaving a substantially different thermal conductivity than the ventcore.
 38. The ventilation apparatus according to claim 37 wherein the atleast one layer is produced on a raw material used to form the vent coreprior to forming the vent core.
 39. The ventilation apparatus accordingto claim 37 wherein the at least one layer is produced on the vent coreafter forming the vent core.
 40. The ventilation apparatus according toclaim 37 wherein the at least one layer is produced on the ventilationapparatus after it has been installed in a building.
 41. The ventilationapparatus according to claim 28 wherein the at least one layer has asubstantially different optical reflectivity than the vent core.
 42. Theventilation apparatus according to claim 41 wherein the at least onelayer is produced on a raw material used to form the vent core prior toforming the vent core.
 43. The ventilation apparatus according to claim41 wherein the at least one layer is produced on the vent core afterforming the core vent.
 44. The ventilation apparatus according to claim41 wherein the at least one layer is produced on the ventilationapparatus after it has been installed in a building.
 45. The ventilationapparatus according to claim 28 wherein the at least one layer isconfigured to mimic the visual appearance and surface texture of asurrounding wall or roof.
 46. The ventilation apparatus according toclaim 28 wherein the at least one layer is produced by a physical vapordeposition process.
 47. The ventilation apparatus according to claim 28wherein the at least one layer is produced by a process or techniqueselected from the group consisting of (a) a chemical vapor deposition orplasma-enhanced chemical vapor deposition process; (b) anelectro-chemical process; (c) a thermal spray process; (d) a laserassisted surface coating process; (e) a plasma transfer arc process; (f)a bonding process; (g) a sol-gel process; (h) a layer-by-layer assemblytechnique; (i) an atomized-spray-plasma deposition process; and (j) alow temperature coating process of painting, spray painting, spincoating, or dip coating.
 48. The ventilation apparatus according toclaim 28 wherein the at least one layer is formed predominantly frommetal.
 49. The ventilation apparatus according to claim 28 wherein theat least one layer is formed predominantly from ceramic.
 50. Theventilation apparatus according to claim 28 wherein the at least onelayer is formed from predominantly one or more dissolved polymers. 51.The ventilation apparatus according to claim 28 wherein the at least onelayer is formed by applying predominantly one or more polymer precursorsand finishing polymerization thereafter.
 52. The ventilation apparatusaccording to claim 28 wherein the at least one layer is formed byapplying predominantly one or more silicones or silicone precursors. 53.The ventilation apparatus according to claim 28 wherein the at least onelayer is formed by applying predominantly at least one syntheticfluoropolymer or its precursors.
 54. The ventilation apparatus accordingto claim 28 wherein the at least one layer is formed by a processselected from the group consisting of: a) embedding at least one type ofnanoparticle in a matrix material; b) depositing predominantly metaloxide nanoparticles embedded in a predominantly polymer based matrix; c)depositing predominantly metal oxide nanoparticles embedded in apredominantly acrylate polymer based matrix; d) depositing predominantlymetal oxide nanoparticles embedded in a predominantly silicone basedmatrix; e) depositing predominantly metal oxide nanoparticles embeddedin a predominantly synthetic fluoropolymer based matrix; f) depositingpredominantly carbon nanoparticles embedded in a predominantly polymerbased matrix; g) depositing predominantly carbon nanoparticles embeddedin a predominantly acrylate polymer based matrix; h) depositingpredominantly carbon nanoparticles embedded in a predominantly siliconebased matrix; i) depositing predominantly carbon nanoparticles embeddedin a predominantly synthetic fluoropolymer based matrix; j) depositingpredominantly naturally occurring nanoparticles embedded in apredominantly polymer based matrix; k) depositing predominantlynaturally occurring nanoparticles embedded in a predominantly acrylatepolymer based matrix; l) depositing predominantly naturally occurringnanoparticles embedded in a predominantly silicone based matrix; m)depositing predominantly naturally occurring nanoparticles embedded in apredominantly synthetic fluoropolymer based matrix; n) depositingpredominantly metal nanoparticles embedded in a predominantly polymerbased matrix; o) depositing predominantly metal nanoparticles embeddedin a predominantly acrylate polymer based matrix; p) depositingpredominantly metal nanoparticles embedded in a predominantly siliconebased matrix; q) depositing predominantly metal nanoparticles embeddedin a predominantly synthetic fluoropolymer based matrix; r) depositing acomposite of a matrix and at least a single type of nanoparticles or amix of different types of nanoparticles and wherein said nanoparticlesare embedded into the matrix; s) depositing predominantly at least onetype of nanoparticle embedded in a matrix of predominantly polymers orpolymer precursors; t) depositing predominantly at least one type ofnanoparticle embedded in a matrix of predominantly silicones or siliconeprecursors; and u) depositing predominantly at least one type ofnanoparticle embedded in a matrix of predominantly syntheticfluoropolymers or synthetic fluoropolymer precursors.
 55. A ventilationapparatus comprising: at least one shape predominantly conforming inpredominantly two dimensions to a structure of one or more componentsfrom which a wall or a roof of a building is made, wherein the twodimensions extend approximately parallel to a plane formed by the wallor the roof, and wherein the apparatus permits airflow into or out ofthe building predominantly through the plane formed by the wall or theroof; a predominantly metallic, plastic, or ceramic vent core; and atleast one layer of material with chemically or physically substantiallydifferent properties than the core, such that at least one functionalcharacteristic of the ventilation apparatus differs compared to anotherventilation apparatus using only the vent core material; wherein the atleast one layer is on the vent core and exhibits the property of beinghydrophobic, super-hydrophobic, icephobic, anti-icing, or anycombinations thereof; and wherein the at least one layer is formed by aprocess selected from the group consisting of: a) embedding at least onetype of nanoparticle in a matrix material; b) depositing predominantlymetal oxide nanoparticles embedded in a predominantly polymer basedmatrix; c) depositing predominantly metal oxide nanoparticles embeddedin a predominantly acrylate polymer based matrix; d) depositingpredominantly metal oxide nanoparticles embedded in a predominantlysilicone based matrix; e) depositing predominantly metal oxidenanoparticles embedded in a predominantly synthetic fluoropolymer basedmatrix; f) depositing predominantly carbon nanoparticles embedded in apredominantly polymer based matrix; g) depositing predominantly carbonnanoparticles embedded in a predominantly acrylate polymer based matrix;h) depositing predominantly carbon nanoparticles embedded in apredominantly silicone based matrix; i) depositing predominantly carbonnanoparticles embedded in a predominantly synthetic fluoropolymer basedmatrix; j) depositing predominantly naturally occurring nanoparticlesembedded in a predominantly polymer based matrix; k) depositingpredominantly naturally occurring nanoparticles embedded in apredominantly acrylate polymer based matrix; l) depositing predominantlynaturally occurring nanoparticles embedded in a predominantly siliconebased matrix; m) depositing predominantly naturally occurringnanoparticles embedded in a predominantly synthetic fluoropolymer basedmatrix; n) depositing predominantly metal nanoparticles embedded in apredominantly polymer based matrix; o) depositing predominantly metalnanoparticles embedded in a predominantly acrylate polymer based matrix;p) depositing predominantly metal nanoparticles embedded in apredominantly silicone based matrix; q) depositing predominantly metalnanoparticles embedded in a predominantly synthetic fluoropolymer basedmatrix; r) depositing a composite of a matrix and at least a single typeof nanoparticles or a mix of different types of nanoparticles andwherein said nanoparticles are embedded into the matrix; s) depositingpredominantly the at least one type of nanoparticle embedded in a matrixof predominantly polymers or polymer precursors; and t) depositingpredominantly at least one type of nanoparticle embedded in a matrix ofpredominantly synthetic fluoropolymers or synthetic fluoropolymerprecursors.
 56. The ventilation apparatus according to claim 55 whereinthe at least one layer is produced by predominantly depositing polymersor polymer precursors.
 57. The ventilation apparatus according to claim55 wherein the at least one layer is produced by predominantlydepositing at least one silicone or silicone precursor.
 58. Theventilation apparatus according to claim 55 wherein the at least onelayer is produced by predominantly depositing at least one syntheticfluoropolymer or its precursor.
 59. The ventilation apparatus accordingto claim 55 wherein the at least one layer is produced on a raw materialused to form the vent core prior to forming the vent core.
 60. Theventilation apparatus according to claim 55 wherein the at least onelayer is produced on the vent core after forming the vent core.
 61. Theventilation apparatus according to claim 55 wherein the at least onelayer is produced on the ventilation apparatus after it has beeninstalled in a building.
 62. The ventilation apparatus according toclaim 55 wherein the at least one layer is directly on the vent core.63. The ventilation apparatus according to claim 55 wherein the at leastone layer is on the vent core, said layer having a substantiallydifferent thermal conductivity than the vent core.
 64. The ventilationapparatus according to claim 63 wherein the at least one layer isproduced on a raw material used to form the vent core prior to formingthe vent core.
 65. The ventilation apparatus according to claim 63wherein the at least one layer is produced on the vent core afterforming the vent core.
 66. The ventilation apparatus according to claim63 wherein the at least one layer is produced on the ventilationapparatus after it has been installed in a building.
 67. The ventilationapparatus according to claim 55 wherein the at least one layer has asubstantially different optical reflectivity than the vent core.
 68. Theventilation apparatus according to claim 67 wherein the at least onelayer is produced on a raw material used to form the vent core prior toforming the vent core.
 69. The ventilation apparatus according to claim67 wherein the at least one layer is produced on the vent core afterforming the core vent.
 70. The ventilation apparatus according to claim67 wherein the at least one layer is produced on the ventilationapparatus after it has been installed in a building.
 71. The ventilationapparatus according to claim 55 wherein the at least one layer isconfigured to mimic the visual appearance and surface texture of asurrounding wall or roof.
 72. The ventilation apparatus according toclaim 55 wherein the at least one layer is produced by a physical vapordeposition process.
 73. The ventilation apparatus according to claim 55wherein the at least one layer is produced by a process or techniqueselected from the group consisting of (a) a chemical vapor deposition orplasma-enhanced chemical vapor deposition process; (b) anelectro-chemical process; (c) a thermal spray process; (d) a laserassisted surface coating process; (e) a plasma transfer arc process; (f)a bonding process; (g) a sol-gel process; (h) a layer-by-layer assemblytechnique; (i) an atomized-spray-plasma deposition process; and (j) alow temperature coating process of painting, spray painting, spincoating, or dip coating.
 74. The ventilation apparatus according toclaim 55 wherein the at least one layer is formed predominantly frommetal.
 75. The ventilation apparatus according to claim 55 wherein theat least one layer is formed predominantly from ceramic.
 76. Theventilation apparatus according to claim 55 wherein the at least onelayer is formed from predominantly one or more dissolved polymers. 77.The ventilation apparatus according to claim 55 wherein the at least onelayer is formed by applying predominantly one or more polymer precursorsand finishing polymerization thereafter.
 78. The ventilation apparatusaccording to claim 55 wherein the at least one layer is formed byapplying predominantly one or more silicones or silicone precursors. 79.The ventilation apparatus according to claim 55 wherein the at least onelayer is formed by applying predominantly at least one syntheticfluoropolymer or its precursors.
 80. The ventilation apparatus accordingto claim 55 wherein the at least one layer contains nanocompositematerials.